ornl is managed by ut-battelle for the us department of energy creep and welding of cf8c-plus and...
TRANSCRIPT
ORNL is managed by UT-Battelle for the US Department of Energy
Creep and Welding of CF8C-Plus and Modified Steels to Enable Commercial Licensing
Principal Investigator:P.J. Maziasz
Lead Division:Materials Science and Technology Division
Co-Investigators:B.A. Pint and N.E. Franco
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Market Opportunity
• Global market for high performance alloys is over $30 billion annually
• CF8C-Plus steel and modified versions could be $3-4 billion over several years for widespread use for chemical/petrochemical, electric power (including gas- and steam-turbines) and transportation exhaust components.
• Forecasts show high performance alloys to grow by 4-5% annually
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Technology Description – Castable CF8C-Plus Steel with Creep Strength at 600-900oC Comparable to Ni-based Superalloys• CF8C-Plus is a new cast austenitic stainless steel
developed by adding Mn and N to standard CF8C steel. It is very castable and requires no additional heat-treatment before service
28 lb Caterpillar regeneration system (CRS) unit, cast by IMPRO, 550 tons
cast from 2006 - 2011
6,700 lb Solar Turbines Mercury 50 end-coverCast by MetalTek, 3 cast from 2005-2012, and one in the field
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Technology Description – Castable CF8C-Plus Steel with Creep Strength at 600-900oC Comparable to Ni-based Superalloy
Larson Miller Parameter (LMP) plotof Creep Rupture at 550-850oC CF8C-Plus compares well with Ni-based
superalloy 617, which costs 7 times more
20
40
60
80
100
300
18,000 20,000 22,000 24,000 26,000 28,000
CF8C
CF8C-Plus
SiMo Cast Iron
Ni-Resist
ST
RE
SS
(M
Pa)
LMP (C=20)
CF8C CF8C-Plus
SiMo Cast Iron
Ni-Resist
20
40
60
80
100
300
21,000 22,000 23,000 24,000 25,000 26,000 27,000 28,000
600 640 680 720 760 800 840
Alloy 617CF8C-PlusCF8C-Plus (in-test)CF8C-Plus+Cu/WCF8C-Plus+Cu/W (in test)
ST
RE
SS
(M
Pa
)
LMP (C=20)
Alloy 617
TEMPERATURE (oC) FOR RUPTURE IN 100,000 HOURS
Stronger!
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Technology Opportunity – CF8C-Plus steel
• ARRA (Stimulus) CF8C-Plus deployment project:– a) developed an ASME Code case (80% complete)
• Required for Boiler & Pressure Vessel applications
– b) performed preliminary welding studies– c) developed new heats of CuW modified CF8C-Plus
with more oxidation resistance at 800°C
• TRL Level is 7-9, U.S. Patent 7,153,373 B2 (Dec.26, 2006), ASTM HG10MNN (2008)
• Additional work is needed to:– a) complete ASME Code Case testing & submit– b) develop and test Fe-base filler welding for ASME
• Currently testing Ni-base weldments for ASME Code Case
– c) generate creep data on modified CF8C-Plus
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Technology Opportunity – CF8C-Plus steel
• The proof demonstrating that the technology works is the CRS commercialization application
The CRS unit regenerates the ceramic diesel particulate filter (DPF) during a 20 min burn cycle at 900oC. 45,000CRS units have operated on heavy-duty truck diesels since late 2006 with no failures (>7y). This is proof of creep and thermal fatigue resistanceand outstanding durability.
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Technology Leadership – CF8C-Plus is unique because Mn and N additions create engineered microstructure for high temperature strength
Creep at 850oC is the performance indicatorthat CF8C-Plus works better than other technologies
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Competitive Differentiation
Technology Feature
ORNLTechnology
Cast irons Cast Stainless
Steels
Cast Stainless
Alloys
Ni-based superalloys
Creepresistance
Fatigue resistance
castability
weldability
cost
Operation up to 950oC
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Applications – Target Customers – Current Practice
Application Description
Target Customers
Current Practice
Pumps and valves
Components in power plants
Babcock&Wilcox, Alstom
9-12Cr martensitic/ferritic steels
Gas -turbines Turbine casing General Electric, Siemens, Alstom
9-12Cr martensitic/ferritic steels
Steam turbines Turbine casing General Electric, Siemens, Alstom
2.25 or 9-12Cr martensitic/ferriticsteels
Pumps, valves and piping
Components in chemical and petrochemical plants
Shell, Dow, Exxon Mobile, MetalTek, Duraloy
CF8, CF8C, CF10M, 347H, HK30Nb, HP40Nb, 800H
turbochargers Turbo housing Honeywell Cast irons, HK30Nb
Exhaust manifolds
Diesel or gasolineExhaust manifolds
Cummins, Ford, GM, Chrysler
Cast irons, HK30Nb
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Contact information for CF8C-Plus steel
• Dr. Philip J. Maziasz
• Oak Ridge National Laboratory, P.O. Box 2008, ms-6115, Oak Ridge, TN 37831-6115
• 865 574-5082 ph